Ample
Ample's goal is to provide accessible power for EVs by creating swapping stations - an automated system that swaps out modular batteries. Drivers no longer wait hours for their batteries to charge, instead getting fresh batteries in a matter of minutes. Ample is deploying its stations around the world which means that they must survive a wide range of environmental conditions.
Note: I am only able to show publically available images of the projects I've worked on at Ample
Wall + Windows
I developed the v2 station's wall and windows from scratch, designing to sustain high wind and snow loads while supporting the weight of the canopy above. The wall is made from steel weldments and mounts panels to fully seal off the inside of the station. The glass windows on the top of the wall were designed using custom aluminum extrusion to complete the sealing and allow for quick installation.
Mechanized Stairs
I designed mechanized stairs that allow users to exit the elevated platform area while a swap is in progress. They comply with OSHA standards and can safely support a 1000lb load. The stairs use the existing platform lift power to raise and lower automatically. Synchronized sheet metal vertical slats cover the inner components to protect users from pinch hazards.
Platform Analysis
I led the analysis of the next-generation swapping station platform ramp that can support a 6000lb single tire load. I switched from a thick sheet metal design to a tubular frame with thin skins to reduce weight and cost while increasing load capability. I used hand calculations and Ansys to size components and ensure the platform could survive heavy vehicles that the station can now support.
Shipping Hardware
In order to make the swapping station mass-production ready, shipping hardware had to be designed that allowed the station components to fit in standard shipping containers and take the load they would see during transportation. I designed, analyzed, and implemented bracketry to flip the battery pods on their sides to allow for this.
